omex zetec focus engine v4 10omextechnology.co.uk/omex zetec focus engine v4_10.pdfford zetec 2.0l...

Ford 2.0L ZetecPerformance Engine Packages

OMEXwww.omextechnology.co.uk

Ford Zetec 2.0L (Focus Blacktop) Engine Packages

Our range of OmexPower engines has been developed to be engine package solutions that are truly ’turn key’. We have developed acoherent range of very high quality, fully tested engine packages with varying power outputs to suit your requirements and budget. All ourengine packages are built on brand new engines. The engines are all built at Omex, mounted on a special jig and hot run. This meansthat the cams are run in, the throttle bodies (where applicable) are balanced, the idle speed is set and the emissions are checked for IVAand MOT compliance. The engines are supplied with the multi championship winning Omex 600 Series ECU and a fully assembled wiringloom manufactured in Raychem DR25 heatshrink as standard. To ensure absolute peace of mind the engine is tested with the actual loomand ECU that are shipped with your engine. As the ECUs are all pre-calibrated there is no need to run any OmexPower engine on a rollingroad or dyno. Simply fit to your car, connect 5 wires (details are of course supplied) and start the engine!

The OmexPower range of Ford Zetec engines covers power outputs of 150 to 200 bhp (normally aspirated). The normally aspiratedengines are available in both inline (to suit front engine rear wheel drive) and transverse (to suit mid engine transverse applications)versions. The supercharged engine is currently available as an inline engine only. The inline engines use the superb RaceLine lowlinefully baffled sump (do not confuse this with cheap inferior copies that are available) whilst the transverse engines use the original Fordaluminium and steel sump.

There are a wide range of mechanical options and upgrades available to suit your requirements, such as 2 manifolds, different clutchesand flywheels, side water rails, a choice of linkages, uprated valve springs etc. The available options for each engine specification aredetailed at the end of each section. In addition there are several electronic options available, such as full throttle gearshift, shift lights andmore, again detailed at the end of each engine. If you would like advice about which specification fits your vehicle best then please giveus a call.

If you would like to see any of our engines, we generally have all specifications available for viewing. In addition we have mostspecifications available in demonstration vehicles. Most of these regularly attend track days and you would be most welcome if you wouldlike a demonstration on track.

Selecting your engine

170-

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throttle response

-170 and 200 bhp versions

-Transverse and inline installations

-Increased power band

-Plenum inlet

-150 bhp

-Transverse and inline installations

-Economical engine package with scope for later

upgrades to other engine packages

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Engine shown is ZE20F022Awith alternator OMEP2100(F)


2Omex Technology Systems Ltd, 3 Mackenzie Way, Manor Road, Cheltenham, GL51 9TX

Tel +44 (0)1242 260656 Fax +44 (0)1242 578069 [email protected] www.omextechnology.co.uk

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Plenum Inlet Zetec Engine - 150 bhp

How much power will my engine make?The power and torque graph shows the results obtained from an engine in a Westfield SEiW, using a Westfield 4-1 exhaust manifold,catalytic convertor, and silencer system. These results are from testing on Omex’s Superflow rolling road.

Engine Power Graphs

PowerTorque

100

125

150

175

2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000RPM

50

75

BH

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Torq

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Zetec Blacktop 2.0 150 bhp Engine Power Graph

ZE20F012

This superb value entry level engine package sacrifices nothing in the way of quality or design, utilising the same high specification billetalloy bracketry and high quality components. Available in both inline (front engine rear wheel drive) and transverse (mid engine)specifications, it uses the standard Ford inlet plenum and throttle body. An idle air bypass valve controlled directly from the multichampionship winning Omex 600 Series ECU provides perfect driveability whatever the temperature. The inline version is fitted with theexcellent RaceLine lowline alloy sump to allow maximum ground clearance whilst the transverse specification uses the Ford alloy and steelsump assembly. Both versions are available with a wide range of upgrades and options to suit your specific requirements.

150 BHP Engine ZE20F012A (inline)150 BHP Engine ZE20F012C (transverse)

Engine--

Engine SpecificationNew Focus Zetec 2.0L Blacktop EngineReady Mapped 600 Series ECUReady Built Wiring HarnessLowline Baffled Sump (inline only)Standard Exhaust Manifold (no cost option)Inlet Manifold with Single Throttle BodyFuel RailFuel Pressure RegulatorThrottle Position SensorAir Temperature SensorCoolant Temperature SensorCrank Position SensorInjectorsIgnition Coil Pack and LeadsOil FilterGaskets


Inline Specification

Engine shown is ZE20F012Cwith alternator OMEP2102(F)

Transverse Specification



Brochure v4.10 04/12/19

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Transverse specification engines are supplied with the standard sump as this is designed for transverse mounting. Inline engines havecornering forces in a different direction on the engine and so the inline specification engines are fitted with a new low line groundclearance sump with internal baffling designed to keep the oil on the pickup. This sump has been tested in vehicles up to single seaterswith slicks and wings generating very high cornering forces.

The standard inlet is used on this engine specification. This gives the option of a remote air filter location so keeping noise to a minimumin the passenger compartment. An ECU controlled idle control valve is used to maintain idle when the engine is cold and heavily loadedby electrical devices such as heated screens, lights etc.

Omex’s multi-championship winning 600 Series ECU controls the fuel injection, standard Ford distributorless ignition coil pack, andoptionally, many other functions around the vehicle. The ECU is connected to the hardware with a complete, ready built wiring harness,which is fully tagged and with the correct connections made for the Zetec engine, ensuring easy clip-on fitment, optimum performanceand absolute reliability. The ECU, wiring harness and sensors are kept with each engine build throughout assembly and testing work,ensuring that the engine package you receive has been tested as a whole package.

Electronics

What comes with the engine?

Inlet System



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Air and coolant temperaturesensors are supplied and fitted.

Bosch injectors are used givingexcellent spray patterns tooptimise power outputs andreduce emissions.

Injectors Temperature Sensors

Crank and throttle positionsensors are supplied and fittedto all engines.

Crank & Throttle Sensors

The engine utilises a fuel pressureregulator built into the fuel rail.

Fuel Pressure Regulator

A good 4-1 exhaust manifold shouldshould be used to achieve the statedpower outputs of the engines. A standardexhaust manifold gasket is included withthe engine. If required the standard FordFocus exhaust manifold can be suppliedwith the engine without additional chargebut should only be used if a reduction inpower output is acceptable.

Exhaust Manifold

All gaskets and an oil filter areincluded and fitted.

Gaskets & Oil Filter

Ignition

DIS coil pack, ignition leads, and spark plugs are all included



Brochure v4.10 04/12/19

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Engine Dimensions (Inline Version)

-Ignition coil pack can be removed and mounted remotely-Exhaust manifold can be replaced with customers own exhaust manifold-Optional side water rail reduces the size of the water housing (see options list)-Oil filter can be changed for a shorter filter

490mm

550m

m

580m

m

Front ofpulleys

Rear ofblock

Rear ofcoil

125mm

Bot

tom

of

sum

pTo

p of

oil

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& c

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125mm

490mm

565mm

Rear ofblock

Rear ofcoil

Front ofpulleys

Back ofWater housing

Cra

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ntre

line

200m

m32

0mm

270mm

455mm

520mm

Cra

nkce

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line

Bot

tom

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p150m

m43

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Top

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Side ofinlet manifold

Side ofexhaust manifold

& water pump

Top

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let m

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320m

m60 m

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ifold

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Brochure v4.10 04/12/19

ZE20F012A engine with alternator OMEP2100(F)

150

bhp

Zete

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Engine Dimensions (Transverse Version)

Engine pictures shown with large flywheel suitable for MTX75 gearboxes, not suitable for IB5 gearboxes. See options for alternativeflywheels and clutch assemblies.


490mm

600m

m

630m

m

Front ofpulleys

Rear ofblock

Rear ofcoil

125mm

Bot

tom

of

sum

pTo

p of

oil

cap

& c

am c

over

125mm

490mm

565mm

Rear ofblock

Rear ofcoil

Front ofpulleys


Cra

nkce

ntre

line

200m

m32

0mm

200mm

420mm

520mmSide of

inlet manifoldSide of

exhaust manifold& water pump

Top

ofin

let m

anifo

ldB

otto

m o

fin

let m

anifo

ld

320m

m60 m

m50 m

m

Cra

nkce

ntre

line

Bot

tom

of

sum

p

200m

m43

0mm

Top

ofca

m c

over

Sid

e of

exha

ust m

anifo

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ump

Sid

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ifold



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ZE20F012C engine with alternator OMEP2102(F)

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8

Options and Upgrades

Wiring Harness Options

Standard ‘Road’ SpecificationThe standard specification harness in this kit is the ‘road’ specification. This harness uses thin wall, lightweight automotive grade cableloomed together with PVC tubing and harness tape; a specification similar to that found on premium modern road cars. Each harnessis individually computer tested to ensure the build is correct.

Rubber connector boots PVC tubing covered cable

Bespoke lengthsTwisted cablesin heatshrink sleeving

Heatshrinkharness joints

Gold platedterminals

Heatshrinkconnector boots

Upgrade 2 – Bespoke ‘Race’ SpecificationThe perfect harness should also fit perfectly. The bespoke ‘Race’ specification is built using the same materials and methods as thestandard ‘Race’ specification harness, but with lengths tailored to suit your engine bay.

Upgrade 1 – ‘Race’ SpecificationThe ‘race’ specification is the same dimensions as the ‘road’ harness and uses the same high grade cable, but this time loomed togetherusing Raychem DR-25 heatshrink as found on nearly every professional motorsport harness for high flexibility, resistance to solventsand superior cut resistance. Within this Raychem outer, the cables are twisted together to provide resistance against radiated electricalnoise from sources such as the high tension sparks, alternator and starter motor giving clean sensor signals to the ECU. The terminalsconnecting to the ECU are then upgraded to gold plating to ensure the best connections to the ECU possible to maintain the cleansignals from the sensors. All joints in the harness are made with crimps rather than solder to withstand the high vibrations often foundwith solidly mounted drivetrains in race vehicles. The joints and the component connectors are then covered in glue lined heatshrinkwhich is inflexible and so any tension placed on the harness during service goes onto the strong connector housings and cables and soaway from the cable joint. All of these improvements together give longer service life and improved reliability in the harsh environmentof a motorsport engine bay. These harnesses are built by a team of engineers currently working in top worldwide ‘works’ motorsportseries (the same team responsible for our ‘works’ spec bespoke harnesses) so not only are high quality materials used, they are builtby the best too. Finally individually computer tested using a state-of-the-art ‘CIRRIS’ test machine at 500V to give extreme testing of thecable insulation.

Twisted cablesin heatshrink sleeving




Omex Technology Systems Ltd, 3 Mackenzie Way, Manor Road, Cheltenham, GL51 9TXTel +44 (0)1242 260656 Fax +44 (0)1242 578069 [email protected] www.omextechnology.co.uk

Brochure v4.10 04/12/19

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Engine Internals Options and Upgrades

For engines that are expected to spend a lot of time at high engine speeds, such as those which are intended for competition use orextended trackday use, extra safety can be inbuilt through the upgrade to ARP big-end bolts and uprated valve springs.

Uprated ARP Big-end bolts Uprated Valve Springs

Mechanical Fitting Options and Upgrades

Starter Motor – For inline specification engines there are two options available, standard remanufactured and new high power startermotors. For transverse specification engines the standard Ford start motor will have to be used.Bellhousing – A cast aluminium bell housing is available to suit the Ford Sierra type 9 (short input shaft) gearbox.Flywheel and Clutch - Flywheel and clutch options are available to suit type 9, IB5, MT75 and MTX75 gearboxes.

Bellhousing for type 9 gearboxStarter Motor Flywheel and Clutch

Side Water Rail – for inline applications where the thermostat housing would hit the bulkhead, the ‘side water rail’ allows the removal ofthe thermostat housing, so allowing the engine to be mounted further back. If a water header tank cannot be fitted to the vehicle, a pressurecap is available for the ‘side water rail’ to remove the need for the header tank. Note that this cannot be used with a standard exhaustmanifold, only with an four branch manifold. To allow extra clearance the ignition coil pack and bracket can be unbolted and mountedremotely. Ignition coil pack can be remotely mounted.

Side water rail Side water rail Standard Water Housing

Alternator - Lightweight hard-anodised billet aluminium brackets are used to mount the high output 2 wire alternator and associated beltpulleys. Transverse and inline specification engines have different belt runs to allow the use of the relevant engine mount positions. Inlinespec alternator setup shown, the transverse spec is similar.



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eWith optional extra parts the Omex 600 ECU is capable of much more than simply running the engine;

Shift lights - a visual warning for the optimum rpm gearshift. Normally a high intensity 10mm red LED is used, but other sizes and coloursare available.Full throttle gearshift - gearshifts without lifting off the throttle. In the case of sequential gearboxes, even without using the clutch.Sequential gearboxes often have a switch inbuilt for input to the ECU, and those using a ‘normal’ gearbox can use an Omex clutch switch,signalling an ignition retard that temporarily reduces engine power output.Launch control - consistent fast starts. A button on the steering wheel that gives a temporary lower rev limit holding the engine steady onthe startline.Radiator fan control - reduce the number of joins and sensors in the cooling system, and have full programmability of the ON / OFFtemperatures for the radiator fan. An additional relay is required for this control.Barometric air pressure correction – If you are using the engine with large altitude changes (such as in the mountainous areas), thenair pressure changes due to the altitude changes will affect the amount of fuel required. An upgrade to fit an air pressure sensor toautomatically make these changes is available.Emissions control - The engine simply needs a narrowband lambda sensor and an effective catalytic convertor and it will then pass UKMOT and IVA emissions tests with ease. Omex can provide a lambda sensor and boss to weld to the exhaust. A lambda sensor is notrequired to make the engine run, so if you have a vehicle that does not need to pass emissions tests, then a lambda sensor is optional.

Shift light (10mm LED) Full throttle gearshift(clutch switch)

Launch control (button) Radiator fan control(Relay and base)

Barometric pressure sensorand harness upgrade

Lambda sensor Lambda sensor boss

Electronic Control Options and Upgrades

Why choose Omex Products?

The difference between winning and losing is very small. In hillclimbing and sprinting it can regularly be 0.05 secs, in circuit racing a halfcars length, in rallying one corner...........

So what makes Omex products win so many events and championships? Simple, attention to DETAIL.

The very basics of how the ECU works makes a big difference. How it calculates when an ignition spark is going to be placed, when it’scalculated, how engine acceleration is taken into account, and so ultimately how accurately that spark is placed, are things that you do notthink about when looking at ECUs. Here at Omex we do because those details that are often taken for granted are the difference betweenone ECU system and another, the difference between winning and losing... The detailed approach to design of the basics by our team oftop software and hardware design engineers, responsible for race wins throughout all forms of motorsport at the very highest levels, meansyou do not need to think about these details because we do. Features lists don’t win races; it’s how these features work that wins races.Other ECUs may have similar features lists, but how an Omex works makes all the difference. Naturally, Omex ECUs have all of thefeatures you would expect from a top level ECU.

Winning Championships is a combination of performance and reliability. Reliability is found in the details of the way the ECU is designedand built. All Omex ECUs are robot assembled in the UK on an ISO9001:2000 approved assembly line, ensuring a consistent, high qualitybuild. They are all then thoroughly tested, twice, before leaving Omex. A well running system is a combination of ECU and many othercomponents. It is important that all components in the system continue to work in order for the ECU to be able to perform, and so Omexsource all other components such as sensors and injectors only from highly respected manufacturers.

Of course, before you can even think about winning races and championships, you need to get to the race! Omex employ only degreequalified engineers to ensure that whenever you contact us you get only the very best advice, right from specification of the best parts foryour application, through to advice during installation, and finally, getting your engine running to its maximum potential.

And should something go wrong at any time during your ownership of your Omex ECU, the same team of technicians is available just atelephone call or mouse click away with free advice to help you through.

All these details have helped countless others win races and championships. Maybe you will be next…



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E&OE. Price list (Retail) valid from 01/11/2012 until further notice. [email protected]%

Engine shown is ZE20F012A with alternator OMEP2100(F)


‘Race’ specification wiring harness upgradeBespoke ‘Race’ specification wiring harness upgrade

Flywheels and clutches (various options available)

Side water rail (complete assembly - fitted)

Starter motor - remanufactured (inline only)

Bellhousing (alloy, to fit Ford type 9 gearbox)

Alternator kit - inlineAlternator kit - transverse

Uprated ARP big-end bolts - fitted to inline specification engineUprated ARP big-end bolts - fitted to transverse specification engineUprated valve springs - fitted to 150 bhp engine

Shift light (10mm LED - red) - inc mounting bezel and cablesShift light (5mm LED - red) - inc mounting bezel and cablesFull throttle gearshift clutch switch - inc cablesLaunch control button - inc cablesRadiator fan control relay and base (fitted)Barometric pressure sensor upgrade, including harness modificationwhen using ‘Road’ spec harnessBarometric pressure sensor upgrade, including harness modificationwhen using ‘Road’ spec harnessLambda (oxygen) sensorLambda sensor boss

Kit

Inline 150 BHP Engine Standard Inlet SystemTransverse 150 BHP Engine Standard Inlet System

Part Number

OMEM1519(U)OMEM1539(U)

OMEP3000(U)(F)

OMEP2000

OMEP3100

OMEP2100(F)OMEP2102(F)

OMEP4100(U)(F)OMEP4110(U)(F)OMEP4000(U)(F)

OMEM6003OMEM6004OMEM6010OMEM6011OMEM5011(F)OMEM2100(U) + OMEM1419A(U)

OMEM2100(U) + OMEM1519A(U)

OMEM2301OMEM2351

ZE20F012AZE20F012C

Retail

£110.00£230.00

Enquire

£265.00

Enquire

Enquire

£380.00£410.00

£150.00£200.00£305.00

£7.80£7.80£6.50£10.00£25.00£95.00

£100.00

£55.00£10.40

£4395.00£3795.00

Inc VAT

£132.00£276.00

Enquire

£318.00

Enquire

Enquire

£456.00£492.00

£180.00£240.00£366.00

£9.36£9.36£7.80£12.00£30.00£114.00

£120.00

£66.00£12.48

£5274.00£4554.00

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Price List: ZE20F012 (150 bhp) Standard Inlet System

Optional parts are standalone extra parts and can be added to your kit at any time. Upgrade parts, designated by a ‘(U)’ in the part number, are upgradeparts in the kit and so are only available at the above prices at the time of kit purchase. They are available at any time, but at the full price of the part.



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How much power will my engine make?The power and torque graph shows the results obtained from an 170 bhp engine in a Westfield SEiW, using a Westfield 4-1 exhaustmanifold, catalytic convertor, and silencer system. The 200 bhp engine in a Caterham, using a Raceline 4-1 exhaust manifold.

Engine Power Graphs

Multiple Throttle Body Inlet Zetec Engine - 170 / 200 bhp

A significant step up from the 150bhp specification in terms of performance, the superb 170bhp specification engine offers a far greaterperformance gain than the 20bhp increase would suggest. Available in both inline (front engine rear wheel drive) and transverse (midengined) specifications, our most popular specification utilises individual throttle butterflies for each cylinder which gives unrestrictedairflow to each cylinder and hence a higher power output. In addition, the ability to produce more power and torque at the higher end ofthe rev range means that the performance gain is much greater than may initially be expected. Also the sound of throttle bodies cannotbe beaten. This engine is ideal for those building a kit car that may be used on track, but which maintains perfect tractability and mannersfor use on the road. The 200bhp specification adds further to this with a beautifully gas flowed cylinder head and bespoke cams, but alsomaintains its perfect road manners whilst offering invigorating performance. Both are available with a wide range of options andupgrades to suit your car perfectly. The inline version is fitted with the excellent RaceLine lowline alloy sump to allow maximum groundclearance whilst the transverse specification uses the Ford alloy and steel sump assembly.


Inline Specification

Engine shown is ZE20F022Cwith alternator OMEP2102(F)

Transverse Specification

PowerTorque

100

125

150

175

2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000RPM

50

75

BH

P /

Torq

ue

Zetec Blacktop 170 bhp Engine Kit Power Graph

ZE20F022

PowerTorque

100

125

150

175

2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000RPM

50

75

BH

P /

Torq

ue

Zetec Blacktop 2.0 200 bhp Engine Power Graph

ZE20F042200

225

200



Engine--

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Engine SpecificationNew Focus Zetec 2.0L Blacktop EngineReady Mapped 600 Series ECUReady Built Wiring HarnessLowline Baffled Sump (inline only)Gas Flowed Head & Inlet Manifold (200 bhp only)Uprated Camshaft (200 bhp engine only)Throttle BodiesInlet ManifoldFuel Rail

Air HornsFuel Pressure RegulatorThrottle Position SensorAir Temperature SensorCoolant Temperature SensorCrank Position SensorInjectorsIgnition Coil Pack and LeadsOil FilterGaskets



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Electronics

What comes with the engines?

Sump

Inline engines have cornering forces in a different direction on the engine to standard and so the inline specification engines are fittedwith a new sump with internal baffling designed to keep the oil on the pickup. This sump has been tested in vehicles up to single seaterwith slicks and wings generating very high cornering forces. Transverse specification engines are supplied with the standard enginesump.

Proven, reliable, Omex throttle bodies are used on these specification engines. Individual throttle plates give the air an unrestricted routeto the engine giving maximum power.

Inlet System

Omex’s multi-championship winning 600 Series ECU controls the fuel injection, standard Ford distributorless ignition coil pack, andoptionally, many other functions around the vehicle. The ECU is connected to the hardware with a complete, ready built wiring harness,which is fully tagged and with the correct connections made for the Zetec engine, ensuring easy clip-on fitment, optimum performanceand absolute reliability. The ECU, wiring harness and sensors are kept with each engine build throughout assembly and testing work,ensuring that the engine package you receive has been tested as a whole package.



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Ignition

DIS coil pack, ignition leads, and spark plugs are all included

Cams

Standard cams are used in the 170 BHP engine. Upratedcams are used in the 200 BHP engine.

Cylinder Head

A standard cylinder head is used on the 170BHP engine.The 200 bhp engine has a superb ported and gas-flowedhead with the inlet manifold port-matched for improved airflow.

The coolant temperature sensoris supplied and fitted. The Airtemperature sensor is suppliedfor mounting in engine bay or airfilter.

Injectors Temperature Sensors

Crank and throttle positionsensors are supplied and fittedto all engines.

Crank & Throttle Sensors

Bosch injectors are used givingexcellent spray patterns tooptimise power outputs andreduce emissions.



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232mm

20o

upgrade straight inlet manifold

All above dimensions and angles are approximate

standard curved inlet manifold

224mm

5o

2 different inlet manifolds exist to enable you to get the perfect fit in yourchassis.

A minimum of 20mm should be allowed between the end of the air hornand the air filter material. Also allow space for the movement of the engine.

The standard manifold curves to put the throttle bodies level when fitted toa level engine.

Lengths between the two kits are possible by changing airhorn length onrequest.

An optional upgrade manifold faces the throttle bodies slightly upwards inline with the port angle to allow maximum airflow.

Inlet Choice

Fuel pressure is regulated by aconstant pressure billet aluminiumhoused regulator.

Fuel Pressure Regulator

An insulating gasket is usedon the inlet manifold to re-duce heat conduction to theinlet and so lower inlet airtemperatures for increasedpower.

Gaskets



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All dimensions are approximate, if you need any other dimensions please ask.

Engine Dimensions (Inline Version)

490mm

550m

m

580m

m

Front ofpulleys

Rear ofblock

Rear ofcoil

125mm

Bot

tom

of

sum

pTo

p of

oil

cap

& c

am c

over

125mm

490mm

565mm

Rear ofblock

Rear ofcoil

Front ofpulleys


Cra

nkce

ntre

line

200m

m31

2mm

270mm

455mm

520mmEnd of

Throttle bodies

Top

ofth

rottl

ebo

dies

Bot

tom

of

thro

ttle

bodi

es 110m

m45 m

m

Cra

nkce

ntre

line

Bot

tom

of

sum

p150m

m43

0mm

Top

ofca

m c

over

Side ofdip stick

& water pump

Sid

e of

dip

stic

k&

wat

er p

ump

End

of

Thro

ttle

bodi

es

275m

m




Brochure v4.10 04/12/19

ZE20F022A engine with alternator OMEP2100(F)

170-

200

bhp

Zete

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All dimensions are approximate if you need any other dimensions please ask.

Engine Dimensions (Transverse Version)

Engine pictures shown with large flywheel suitable for MTX75 gearboxes, not suitable for IB5 gearboxes. See options for alternativeflywheels and clutch assemblies.


490mm

600m

m

630m

m

Front ofpulleys

Rear ofblock

Rear ofcoil

125mm

Bot

tom

of

sum

pTo

p of

oil

cap

& c

am c

over

200mm

408mm

512mmSide of

inlet manifoldSide ofdip stick

& water pump

Cra

nkce

ntre

line

Bot

tom

of

sum

p

200m

m43

0mm

Top

ofca

m c

over

125mm

490mm

565mm

Rear ofblock

Rear ofcoil

Front ofpulleys


Cra

nkce

ntre

line

200m

m31

2mm

Sid

e of

dip

stic

k&

wat

er p

ump

End

of

Thro

ttle

bodi

es

Top

ofth

rottl

ebo

dies

Bot

tom

of

thro

ttle

bodi

es 110m

m45 m

m27

5mm



Brochure v4.10 04/12/19

ZE20F022C engine with alternator OMEP2102(F)

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Brochure v4.10 04/12/19


Wiring Harness Options

Standard ‘Road’ SpecificationThe standard specification harness in this kit is the ‘road’ specification. This harness uses thin wall, lightweight automotive grade cableloomed together with PVC tubing and harness tape; a specification similar to that found on premium modern road cars. Each harnessis individually computer tested to ensure the build is correct.

Rubber connector boots PVC tubing covered cable

Bespoke lengthsTwisted cablesin heatshrink sleeving




Upgrade 2 – Bespoke ‘Race’ SpecificationThe perfect harness should also fit perfectly. The bespoke ‘Race’ specification is built using the same materials and methods as thestandard ‘Race’ specification harness, but with lengths tailored to suit your engine bay.

Upgrade 1 – ‘Race’ SpecificationThe ‘race’ specification is the same dimensions as the ‘road’ harness and uses the same high grade cable, but this time loomed togetherusing Raychem DR-25 heatshrink as found on nearly every professional motorsport harness for high flexibility, resistance to solventsand superior cut resistance. Within this Raychem outer, the cables are twisted together to provide resistance against radiated electricalnoise from sources such as the high tension sparks, alternator and starter motor giving clean sensor signals to the ECU. The terminalsconnecting to the ECU are then upgraded to gold plating to ensure the best connections to the ECU possible to maintain the cleansignals from the sensors. All joints in the harness are made with crimps rather than solder to withstand the high vibrations often foundwith solidly mounted drivetrains in race vehicles. The joints and the component connectors are then covered in glue lined heatshrinkwhich is inflexible and so any tension placed on the harness during service goes onto the strong connector housings and cables and soaway from the cable joint. All of these improvements together give longer service life and improved reliability in the harsh environmentof a motorsport engine bay. These harnesses are built by a team of engineers currently working in top worldwide ‘works’ motorsportseries (the same team responsible for our ‘works’ spec bespoke harnesses) so not only are high quality materials used, they are builtby the best too. Finally individually computer tested using a state-of-the-art ‘CIRRIS’ test machine at 500V to give extreme testing of thecable insulation.

Twisted cablesin heatshrink sleeving




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Brochure v4.10 04/12/19

Throttle linkage – single and twin cable versions are available. They are supplied pre-built onto the throttle bodies assembly and may beadjusted to give the best throttle action. They can be fitted above or below the throttle bodies with the cable feeding to the left or right,please specify when ordering. When being fitted to the short throttle bodies the linkage can only be under slung.

Twin cable throttle linkage kit(top mounting)

Mechanical Fitting Options and Upgrades

Engine Internals Options and Upgrades

For engines that are expected to spend a lot of time at high engine speeds, such as those which are intended for competition use orextended trackday use, extra safety can be inbuilt through the upgrade to ARP big-end bolts and uprated valve springs.

Uprated Big-end bolts Uprated Valve Springs

OMEX POWER

Air filter and back plate

110mm 440mm

190m

m

Filter adds 70mm to the length of the long throttle bodies.

Air filtration – the throttle bodies will accept DCOE / DHLA pattern backplate air filters.

Single cable throttle linkage kit(top mounting)

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Side Water Rail – for inline applications where the thermostat housing would hit the bulkhead, the ‘side water rail’ allows the removal ofthe thermostat housing, so allowing the engine to be mounted further back. If a water header tank cannot be fitted to the vehicle, a pressurecap is available for the ‘side water rail’ to remove the need for the header tank. To allow extra clearance the ignition coil pack and bracketcan be unbolted and mounted remotely. Ignition coil pack can be remotely mounted.

Side water rail Side water rail Standard Water Housing

Starter Motor – For inline specification engines there are two options available, standard remanufactured and new high power startermotors. For transverse specification engines the standard Ford start motor will have to be used.Bellhousing – A cast aluminium bell housing is available to suit the Ford Sierra type 9 (short input shaft) gearbox.

BellhousingStarter Motor

Flywheel and Clutch

Flywheel and Clutch - Flywheel and clutch options are available to suit type 9, IB5, MT75 and MTX75 gearboxes.

Fuel pipe – the engine package is as standard for use with push-on rubber pipe. For those using braided hosing throughout the vehicle,an upgrade to dash 6 pipe fittings is available for the fuel rail and pressure regulator.Brake servos – if your vehicle requires a brake servo vacuum, the manifold can be fitted with a vacuum take-off. This can be specified toexit to the either side of the engine.

Push-on to screw-on fuel rail and pressureregulator upgrade (-6)

Brake servo adaptor

Alternator - Lightweight hard-anodised billet aluminium brackets are used to mount the high output 2 wire alternator and associated beltpulleys. Transverse and inline specification engines have different belt runs to allow the use of the relevant engine mount positions. Inlinespec alternator setup shown, the transverse spec is similar.



Brochure v4.10 04/12/19

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With optional extra parts the Omex 600 ECU is capable of much more than simply running the engine;

Shift lights - a visual warning for the optimum rpm gearshift. Normally a high intensity 10mm red LED is used, but other sizes and coloursare available.Full throttle gearshift - gearshifts without lifting off the throttle. In the case of sequential gearboxes, even without using the clutch.Sequential gearboxes often have a switch inbuilt for input to the ECU, and those using a ‘normal’ gearbox can use an Omex clutch switch,signalling an ignition retard that temporarily reduces engine power output.Launch control - consistent fast starts. A button on the steering wheel that gives a temporary lower rev limit holding the engine steady onthe startline.Radiator fan control - reduce the number of joins and sensors in the cooling system, and have full programmability of the ON / OFFtemperatures for the radiator fan. An additional relay is required for this control.Barometric air pressure correction – If you are using the engine with large altitude changes (such as in the mountainous areas), thenair pressure changes due to the altitude changes will affect the amount of fuel required. An upgrade to fit an air pressure sensor toautomatically make these changes is available.Emissions control - The engine simply needs a narrowband lambda sensor and an effective catalytic convertor and it will then pass UKMOT and IVA emissions tests with ease. Omex can provide a lambda sensor and boss to weld to the exhaust. A lambda sensor is notrequired to make the engine run, so if you have a vehicle that does not need to pass emissions tests, then a lambda sensor is optional.

Shift light (10mm LED) Full throttle gearshift(clutch switch)

Launch control (button) Radiator fan control(Relay and base)

Barometric pressure sensorand harness upgrade

Lambda sensor Lambda sensor boss

Electronic Control Options and Upgrades

Why choose Omex Products?

The difference between winning and losing is very small. In hillclimbing and sprinting it can regularly be 0.05 secs, in circuit racing a halfcars length, in rallying one corner...........

So what makes Omex products win so many events and championships? Simple, attention to DETAIL.

The very basics of how the ECU works makes a big difference. How it calculates when an ignition spark is going to be placed, when it’scalculated, how engine acceleration is taken into account, and so ultimately how accurately that spark is placed, are things that you do notthink about when looking at ECUs. Here at Omex we do because those details that are often taken for granted are the difference betweenone ECU system and another, the difference between winning and losing... The detailed approach to design of the basics by our team oftop software and hardware design engineers, responsible for race wins throughout all forms of motorsport at the very highest levels, meansyou do not need to think about these details because we do. Features lists don’t win races; it’s how these features work that wins races.Other ECUs may have similar features lists, but how an Omex works makes all the difference. Naturally, Omex ECUs have all of thefeatures you would expect from a top level ECU.

Winning Championships is a combination of performance and reliability. Reliability is found in the details of the way the ECU is designedand built. All Omex ECUs are robot assembled in the UK on an ISO9001:2000 approved assembly line, ensuring a consistent, high qualitybuild. They are all then thoroughly tested, twice, before leaving Omex. A well running system is a combination of ECU and many othercomponents. It is important that all components in the system continue to work in order for the ECU to be able to perform, and so Omexsource all other components such as sensors and injectors only from highly respected manufacturers.

Of course, before you can even think about winning races and championships, you need to get to the race! Omex employ only degreequalified engineers to ensure that whenever you contact us you get only the very best advice, right from specification of the best parts foryour application, through to advice during installation, and finally, getting your engine running to its maximum potential.

And should something go wrong at any time during your ownership of your Omex ECU, the same team of technicians is available just atelephone call or mouse click away with free advice to help you through.

All these details have helped countless others win races and championships. Maybe you will be next…



Brochure v4.10 04/12/19

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Kit


Inlet manifold upgrade

‘Race’ specification wiring harness upgradeBespoke ‘Race’ specification wiring harness upgrade

Throttle linkage single cableThrottle linkage twin cable

Air filter and machined back plate (long throttle bodies only)

Push-on to screw-on fuel rail and pressure regulator upgradeBrake servo adaptors

Side water rail (complete assembly - fitted)

Flywheels and clutches (various options available)

Starter motor (remanufactured)

Bellhousing (alloy, to fit Ford type 9 gearbox)

Alternator kit - inlineAlternator kit - transverse

Uprated ARP big-end bolts - fitted to inline specification engineUprated ARP big-end bolts - fitted to transverse specification engine

Uprated valve springs - fitted to 170 bhp engineUprated valve springs - fitted to 200 bhp engine

Shift light (10mm LED - red) - inc mounting bezel and cablesShift light (5mm LED - red) - inc mounting bezel and cablesFull throttle gearshift clutch switch - inc cablesLaunch control button - inc cablesRadiator fan control relay and base (fitted)Barometric pressure sensor upgrade, including harness modificationwhen using ‘Road’ spec harnessBarometric pressure sensor upgrade, including harness modificationwhen using ‘Road’ spec harnessLambda (oxygen) sensorLambda sensor boss

Retail

£0.00

£110.00£230.00

£103.00£158.00

£112.00

£8.00£30.00

£265.00

Enquire

Enquire

Enquire

£380.00£410.00

£150.00£200.00

£305.00£230.00

£7.80£7.80£6.50£10.00£25.00£95.00

£100.00

£55.00£10.40

£5495.00£4895.00

£7795.00£7195.00

Inline 170 bhp Engine with Long Throttle BodiesTransverse 170 bhp Engine with Long Throttle Bodies

Inline 200 bhp Engine with Long Throttle BodiesTransverse 200 bhp Engine with Long Throttle Bodies

Part Number

OM003(U)

OMEM1519(U)OMEM1539(U)

CL1-SingleCL1-Twin

AFFB+AFBA/93.6

FPR535-6(U) + FRA/93.6-6(U)OMEM9100

OMEP3000(U)(F)

OMEP2000

OMEP3100

OMEP2100(F)OMEP2102(F)

OMEP4100(U)(F)OMEP4110(U)(F)

OMEP4000(U)(F)OMEP4010(U)(F)

OMEM6003OMEM6004OMEM6010OMEM6011OMEM5011(F)OMEM2100(U) + OMEM1419A(U)

OMEM2100(U) + OMEM1519A(U)

OMEM2301OMEM2351

ZE20F022AZE20F022C

ZE20F042AZE20F042C

Inc VAT

£0.00

£132.00£276.00

£123.60£189.60

£134.40

£9.60£36.00

£318.00

Enquire

Enquire

Enquire

£456.00£492.00

£180.00£240.00

£366.00£276.00

£9.36£9.36£7.80£12.00£30.00£114.00

£120.00

£66.00£12.48

£6594.00£5874.00

£9354.00£8634.00

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Price List: ZE20F022 and ZE20F042 (170/200 bhp) Throttle Bodies Inlet System

E&OE. Price list (Retail) valid from 01/11/2012 until further notice. [email protected]%

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Engine shown is ZE20F022A with alternator OMEP2100(F)

Optional parts are standalone extra parts and can be added to your kit at any time. Upgrade parts, designated by a ‘(U)’ in the part number, are upgrading parts in the kit and so areonly available at the above prices at the time of kit purchase. They are available at any time, but at the full price of the part.



Brochure v4.10 04/12/19

omex zetec focus engine v4 10omextechnology.co.uk/omex zetec focus engine v4_10.pdfford zetec 2.0l...

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